Wheel lathe for railroad cars and locomotives

ABSTRACT

One embodiment of the invention relates to an apparatus for configuring a wheel associated with a train. The apparatus comprises a tool configured to engage the wheel; a compound slide system for positioning the cutting tool in at least two axes; and a computer control coupled to control the compound slide system. The compound slide system is controlled so that the wheel is configured in accordance with a profile.

FIELD

The present disclosure relates generally to the field of maintenance forrailway vehicles. More specifically, the present disclosure relates toan apparatus for machining and maintaining the wheels of a locomotive orrailway car.

BACKGROUND OF THE INVENTION

Wheels on railway locomotives and cars are subject to abuse and wear inthe course of normal use. This wear changes the contour of the wheel,forming undesirable contours including flats, high flanges and othercontours that adversely affect the performance of the wheel. A wornwheel can reduce ride quality, increase the risk of derailments, andcontribute to increased wear, fatigue, noise, and excessive fuelconsumption.

Locomotive and railcar wheel maintenance is important to safety andefficient operation of railways. Locomotive and railcar wheelmaintenance typically involves removing the locomotive or railcar fromservice and re-profiling or “retruing” the wheel with a lathe mechanism.Such known lathe mechanisms may be provided in pits below removable railsections. Such mechanisms may be computer numerical control (CNC)machines and are generally large, expensive, and not portable.Stationary mechanisms require establishing a permanent maintenancefacility or area and removing the locomotive or railcar from service.

Locomotive and railcar wheels may also be re-profiled with manual lathemechanisms. However, such manual processes are generally time-consumingand require intense labor, taking as many as 8 hours to re-profile apair of wheels. In addition, some known processes create a long,continuous chip. A machinist is required to wear safety gear such asheavy leather clothing and a face shield to avoid being injured by theextremely hot, razor sharp chips.

Thus, there is a need for a portable re-profiling system for wheels oflocomotives or railcars. Furthermore, there is a need for a lathemechanism that is more efficient and safer than manual lathe mechanisms.Further still, there is a need for an automated re-profiling system thatis quick, efficient and less expensive than conventional systems locatedin permanent maintenance facilities.

SUMMARY OF THE INVENTION

One embodiment of the invention relates to an apparatus for configuringa wheel associated with a train. The apparatus comprises a cutting toolor a grinding tool configured to engage the wheel; a compound slidesystem for positioning the cutting tool in at least two axes; and acomputer control coupled to control the compound slide system. Thecompound slide system is controlled so that the wheel is configured inaccordance with a profile.

Another embodiment relates to a method of profiling a wheel whileattached to a railcar or locomotive on a rail. The method comprisesdisengaging the wheel from the rail. The wheel is ordinarily attached tothe railcar or locomotive. The method also includes attaching a portablemill or lathe machine to the track; rotating the wheel; and profilingthe wheel in accordance with a stored profile in the portable mill orlathe machine.

Still another embodiment relates to a system for profiling a wheel inaccordance with an electronically stored profile. The wheel isassociated with a train. The system comprises a lathe cutting toolconfigured to engage the wheel; a compound positioning system forpositioning the cutting tool in at least two axes; and a computercontrol for controlling the compound positioning system. The compoundsystem is controlled so that the wheel is shaped in accordance with theprofile.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a an isometric view of a railroad car according to anexemplary embodiment.

FIG. 2 is a block diagram of an apparatus for re-profiling a wheel for arailroad car of FIG. 1 according to an exemplary embodiment.

FIGS. 3A and 3B are isometric views of an apparatus for re-profiling awheel for a railroad car of FIG. 1 according to an exemplary embodiment.

FIG. 4 is top view of the apparatus of FIG. 2 for re-profiling a wheelfor a railroad car.

FIG. 5 is a bottom isometric view of the apparatus of FIG. 2, showing amechanism for coupling the apparatus to a rail.

FIGS. 6-7 are isometric views of a drive mechanism for the apparatus ofFIG. 2 according to one exemplary embodiment.

FIG. 8 is an isometric view of a cutting tool for the apparatus of FIG.2 according to an exemplary embodiment.

FIGS. 9A-9B are top views of two exemplary wheel profiles for a wheelfor the railcar of FIG. 1.

FIG. 10 is a flowchart of a method for profiling a wheel according to anexemplary embodiment.

FIG. 11 is a top view of an apparatus for re-profiling a wheel for arailroad car according to another exemplary embodiment.

FIG. 12 is a front view of a drive mechanism for an apparatus forre-profiling a wheel for a locomotive according to an exemplaryembodiment.

FIGS. 13 and 14 are isometric views of a drive mechanism for anapparatus for re-profiling a wheel for a railroad car according toanother exemplary embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring in general to the FIGURES and more specifically to FIGS. 2-4,an apparatus 20 for profiling or re-profiling the wheels 12 of a railcar10 is shown according to an exemplary embodiment. For the purpose ofthis specification and the claims, railroad cars include any wheeledsystems configured for riding on railroad tracks or rails, including,for example, a locomotive 11 and a railcar 10 shown in FIG. 1. Apparatus20 is a computer controlled lathe apparatus that is configured to becoupled to tracks 18 upon which locomotive 11 or railcar 10 rides.

Apparatus 20 is a portable lathe device that is configured to be coupledto the track or rail 18 upon which wheels 12 of a railcar 10 areresting. To provide a precise profile for wheel 12 with a relativelyshort cycle time, apparatus 20 is a computer numerical control (CNC)lathe. The desired profile 82 for wheel 12 and the cutting path neededto provide the profile for wheel 12 is stored in a computer control 80coupled to apparatus 20. Apparatus 20 includes a cutting tool 24 with aninsert 26. A profile for wheel 12 is provided by rotating wheel 12 andmoving cutting tool 24 relative to wheel 12 with a 2-axis slidemechanism 30. A user may operate an interface 84 coupled to computercontroller 80 to control apparatus 20.

Apparatus 20 is able to be easily moved to a railcar 10 or locomotive 11anywhere instead of having to move the railcar 10 or locomotive 11 toapparatus 20. While most existing mechanisms can weigh in access ofseveral tons, apparatus 20 weighs approximately 450 lbs. Apparatus 20,for example, may be used to service a railcar 10 or locomotive 11 thatis broken down at a location away from a station or service area.According to one exemplary embodiment, apparatus 20 wheels may becoupled to apparatus 20. According to another exemplary embodiment,apparatus 20 may be transported by a vehicle such as a forklift.

As shown best in FIG. 5, apparatus 20 is coupled to rail 18 with amounting mechanism 90. Mounting mechanism 90 rides on the top of a rail18 aligned with a wheel 12 to be machined. Mounting mechanism 90 isconfigured to support apparatus 20 such that apparatus is level, firmlycoupled to rail 18, and rotated to be aligned with wheel 12. Accordingto an exemplary embodiment, mounting mechanism 90 includes a plate ormain body 92, one or more clamps 96, a location bar 100, and a push bar108.

Location bar 100 is placed along the edge of rail 18 to locate apparatus20 above rail 18 (e.g., so that the apparatus 20 is approximatelyaligned with rail 18). Wheels 12 and axle 14 may be configured to rotateslightly about a vertical axis (e.g., to facilitate railcar 10, 11moving along curved rails). When railcar 10, 11 is elevated from rails18, wheels 12 and axle may rotate about this horizontal axis. Themagnitude and direction of this rotation is generally unpredictable. Tocompensate for the rotation and to align apparatus 20 with wheel 12,location bar 100 is coupled to plate 92 with a pinned connection (notshown) provided generally in the middle of location bar 100. Locationbar 100 includes one or more holes 102, that are aligned withcorresponding slots 104 (FIG. 4) in plate 92. Once apparatus 20 isrotated so it is aligned with wheel 12, fasteners passing through holes102 are tightened to prevent apparatus 20 from rotating about the pinnedconnection of location bar 100.

Clamps 96 are movable in a direction generally perpendicular to rail 18.Clamps 96 are coupled to plate 92 by a fastener that passes through ahole 98 in clamp 96 and a corresponding slot 94 in plate 92. Accordingto one exemplary embodiment, clamps 96 are coupled to plate 92 with abolt that engages a nut. As the bolt is tightened, the head of the boltand the nut compress clamp 96 against plate 92, preventing clamp 96 frommoving relative to plate 92. When apparatus 20 is placed on rail 18,clamps 96 are moved to compress rail 18. A push rod 108 (FIG. 12) isprovided to limit the movement of apparatus 20 perpendicular to rail 18.One end of push rod 108 is coupled to apparatus while the opposite endextends to contact the opposite rail 18 (e.g. the rail apparatus 20 isnot resting on) or another suitable stationary object.

According to one exemplary embodiment, apparatus 20 is leveled (e.g., socutting tool 24 moves along a horizontal plane). A multitude of threadedholes 106 are provided about the periphery of plate 92. Holes 106receive leveling mechanisms such as threaded rods (not shown) with anend that contacts the ground. By turning the leveling mechanisms, theymove in a vertical direction relative to plate 92 and move variousportions of plate 92 and, in turn, apparatus 20, up or down. Accordingto one exemplary embodiment, holes 106 are provided at each corner ofplate 92. According to other exemplary embodiments, holes 106 may beprovided elsewhere (e.g., along a side of plate 92).

As shown best in FIG. 8, cutting tool 24 includes an insert 26 that issecured with an insert clamp 28 (e.g., retainer, holder, etc.). Theedges of wheels 12 being profiled may include imbedded sand, stones, andother foreign debris. Cutting tool 24 includes a high-quality cuttingtool insert 26 that is able to withstand the wear from the imbeddedparticles. According to one exemplary embodiment, insert 26 is formedfrom a tungsten carbide material. According to other exemplaryembodiments, insert 26 may be formed from cermet, a coated carbide, aceramic material, or any other suitable material known in the art. Whileinsert 26 is shown as a generally cylindrical member in FIGS. 3 and 8,according to other exemplary embodiments it may have a wide variety ofgeometries.

Wheel 12 is turned so cutting tool 24 can profile the entirecircumference of wheel 12 with a drive mechanism 50. Drive mechanism 50includes a base 51, power source such as drive motor 52, a gear reducer54, and a sprocket 56 coupled to a wheel 12 opposite of the wheel 12 tobe profiled (e.g. on the same axle 14). Sprocket 56 is bolted orotherwise coupled to the end of wheel 12 opposite of wheel 12 to beprofiled. Because both wheels 12 are mounted on the same solid axle 14,turning one wheel also turns the other. Gear reducer 54 is providedbetween drive motor 52 and sprocket 56 to reduce the rotational speed towheel 12 and increase the torque to wheel 12. The output shaft of gearreducer 54 is coupled to sprocket 56 with a chain 58. According to otherexemplary embodiments, wheel could be driven by other means (e.g., amotor coupled directly to the wheel, with a roller contacting the edgeof the wheel, etc.). According to an exemplary embodiment, wheel 12 Iturned a approximately 30-40 revolutions per minute. According to otherexemplary embodiments, wheel 12 may be turned a another rate dependingon a variety of factors, including the cutting tool material, cuttingtool geometry, motor speed, etc. According to one exemplary embodiment,drive motor 52 is a 15 hp AC motor and gear reducer 54 provides a gearreduction ration of 40:1.

Referring to FIGS. 13 and 14, according to another exemplary embodiment,a drive mechanism 150 uses a friction wheel to turn wheel 12 and axle14. Drive mechanism is similar to drive mechanism 50, but includes adrive motor 152 that turns a friction wheel such as a rubber roller 157.Roller 157 is compressed against a wheel 12 opposite of the wheel 12 tobe profiled (e.g. on the same axle 14). A gear reducer may be providedbetween drive motor 152 and roller 157. Roller 157 is rotated by motor152 and, in turn, rotates wheels 12 and axle 14.

Cutting tool 24 is coupled to a slide mechanism 30 that allows cuttingtool 24 to be movable relative to wheel 12 along both an x-axis 40 and ay-axis 42. Slide mechanism includes a first slide 31 that moves alongx-axis 40, parallel to axle 14, and a second slide 35 that moves alongy-axis 42, perpendicular to axle 14. A first power source 32 is providedto move first slide 31. A second power source 36 is provided to movesecond slide 35. As described above, according to one exemplaryembodiment, apparatus 20 is a CNC lathe, and power sources 32 and 36 areelectric motors (e.g., servo motors, stepper motors, etc.) that arecontrolled with signals from a computer controller. Power sources 32 and36 are coupled to gear reducers 33 and 37, respectively. Gear reducers33 and 37 reduce the shaft speed and increase the torque from powersources 32 and 36. According to various exemplary embodiments, gearreducers 33 and 37 may be directly coupled to the slide mechanism or maybe coupled to the slide mechanism through a transfer mechanism.

As shown according to one exemplary embodiment in FIG. 3, power source32 and gear reducer 33 are coupled directly to the threaded drive shaft110 for first slide 31 while power source 36 and gear reducer 37 arecoupled to the threaded drive shaft 112 of second slide 35 throughtransfer mechanism 38. Transfer mechanism 38 may be any mechanism thatsuitably transfers rotational power, such as a belt and pulleymechanism, a chain and sprocket mechanism, or a gear set. According toan exemplary embodiment, transfer mechanism 38 includes a timing belt(not shown) that engages two pulleys. Transfer mechanisms may beprovided to reposition power sources (e.g., to provide a more compactapparatus 20), and/or, to further lower or raise the rotational speed ofthe drive shafts for slide mechanism 30 (e.g., by providing twodifferently sized pulleys or sprockets or a reducing gear set). A guardor casing (not shown) may be provided to prevent inadvertent contactbetween a person or object and the moving components of transfermechanism 38. According to one exemplary embodiment, power sources 32and 36 are servo motors and gear reducers 33 and 37 are 20:1 gearreducers. According to other exemplary embodiments, power source 32 and36 may be a hand wheel with tracer system.

Second slide 35 may be configured to rotate about a vertical axisrelative to base 22 and mounting mechanism 90. According to an exemplaryembodiment, second slide 35 can be locked at two positions 180 degreesapart to service both wheels 12 on axle 14 while engaging the insideedge of either rail 18 by reorienting mounting mechanism 90 relative tosecond slide 35.

As cutting tool 24 profiles wheel 12, it may form a chip of removedmaterial. Because apparatus 20 profiles wheel 12 with an automated CNCprocess, a user does not need to be in close proximity to wheel 12 as itis being machines, reducing the chance of the user being cut by thechip.

Referring now to FIG. 10, a method for profiling wheels 12 on a railcar10 or locomotive 11 involve first disengaging wheels 12 from rails 18(step 70). According to an exemplary embodiment, a jack or lift 19 (FIG.12) is used to raise one set of wheels 12 off of rails 18 while leavingthe other set of wheels engaged. Wheels 12 and axle 14 are both leftcoupled to railcar 10 or locomotive 11 to reduce the amount of timeneeded to profile wheels 12.

After wheels 12 have been disengaged from rails 18, apparatus 20 iscoupled to rails 18 proximate to a wheel 12 with mounting mechanism 90(step 72). The position of cutting tool 24 relative to wheel 12 iscalibrated by first touching cutting tool 24 to wheel 12 at severalplaces and storing those positions in the computer controller. Accordingto one exemplary embodiment, as shown in FIGS. 9A and 9B, cutting tool24 is touched to wheel 12 at four places. A first point 60 is on top ofthe flange 13 of wheel 12. A second point 62 is on the outside edge or“rim” 17 of wheel 12. A third point 64 and a fourth point 66 are on thetwo contact points of the “tread” 15.

Wheel 12 is rotated so cutting tool 24 can profile the entirecircumference of wheel 12 (step 74). If 11 is a locomotive, wheel 12 maybe a driving wheel. However, powering the locomotive would cause all thedriving wheels on locomotive 11 to turn. To turn only the wheel beingprofiled by apparatus 20, an external power source is used. According toone exemplary embodiment, shown in FIG. 12, wheel 12 is turned bypowering the traction motor 122 with a portable power source 120 such asa DC welder. If railcar 10 is an unpowered car, such as a box car, wheel12 is turned by a chain and sprocket drive mechanism 50, as shown inFIGS. 6 and 7 or a friction wheel drive mechanism 150, as shown in FIGS.13 and 14.

With wheel 12 rotating, cutting tool 24 profiles wheel 12 in accordancewith a stored profile 82 in the computer controller 80 (step 76).Cutting tool 24 is moved by slide mechanism 35 along x-axis 40 andy-axis 42 with drive motors 32 and 36. According to one exemplaryembodiment, apparatus 20 may be used to machine wheel 12 to an AAR-IBregular flange profile (FIG. 9A) or an AAR-IB narrow flange profile(FIG. 9B). According to other exemplary embodiments, the computercontroller may provide other paths to apparatus 20 to machine wheel 12to another profile.

Once wheel 12 has been profiled by apparatus 20, railcar 10 orlocomotive 11 is lowered back onto rails 18 (step 78). Railcar 10 orlocomotive 11 may then be raised again to profile the other wheels or,if all wheels have been profiled, railcar 10 or locomotive 11 may bereturned to service.

Referring now to FIG. 11, according to another exemplary embodiment,apparatus 20 used to profile wheel 12 is not a CNC lathe. Instead, atemplate 122 provides a path for cutting tool 24 of apparatus 20 whilean operator moves cutting tool 24 with a manual slide mechanism 130. Ahand wheel 132 is turned to move first slide 31 along drive shaft 110and a second hand wheel 136 is turned to move second slide 35 alongdrive shaft 112. Template 122 includes a profile 124 that describes adesired profile for wheel 12. Template 122 is positioned relative towheel 12 such that an arm 120 extending from apparatus 20 contactstemplate 122 at a position analogous to the position of cutting tool 24relative to wheel 12. The position of template 122 is calibrated byfirst touching cutting tool 24 to wheel 12 at several places andpositioning template 122 such that arm 120 contacts template 122 at thesame places. The calibration points may be similar to the calibrationpoints used to calibrate the CNC process described above or may bedifferent points.

For the purpose of this disclosure, the term “coupled” means the joiningof two members directly or indirectly to one another. Such joining maybe stationary in nature or moveable in nature. Such joining may beachieved with the two members or the two members and any additionalintermediate members being integrally formed as a single unitary bodywith one another or with the two members or the two members and anyadditional intermediate members being attached to one another. Suchjoining may be permanent in nature or may be removable or releasable innature.

It is important to note that the construction and arrangement of thewheel mill as shown in the various exemplary embodiments is illustrativeonly. Although only a few embodiments of the present inventions havebeen described in detail in this disclosure, those skilled in the artwho review this disclosure will readily appreciate that manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages presented in the present application.Accordingly, all such modifications are intended to be included withinthe scope of the present disclosure. Other substitutions, modifications,changes and omissions may be made in the design, operating conditionsand arrangement of the various exemplary embodiments without departingfrom the scope of the present disclosure.

1. A method of profiling a wheel while attached to a railcar orlocomotive on a rail, the method comprising: disengaging the wheel fromthe rail, the wheel being attached to the railcar or locomotive;attaching a lathe machine to the rail; rotating the wheel using a motorassociated with the locomotive; and profiling the wheel in accordancewith a stored profile in the lathe machine.
 2. A method of profiling awheel while attached to a railcar or locomotive on a rail, the methodcomprising: disengaging the wheel from the rail, the wheel beingattached to the railcar or locomotive; attaching a lathe machine to therail; rotating the wheel; and profiling the wheel in accordance with astored profile in the lathe machine, the profile being a standardprofile of a standard flange profile or a narrow flange profile.
 3. Anapparatus for configuring a wheel associated with a train, the apparatuscomprising: an interface configured to secure the apparatus to a railassociated with a train track; a tool configured to engage the wheel; acompound slide system for positioning the cutting tool in at least twoaxes; and a computer control coupled to control the compound slidesystem, wherein the compound slide system is controlled so that thewheel is configured in accordance with a profile, wherein the interfaceincludes a member having a first end coupled to the apparatus and asecond end configured to engage an opposite rail, the member beingconfigured to limit the movement of the apparatus in a direction that issubstantially perpendicular to the rail.
 4. A method of profiling awheel while attached to a railcar or locomotive on a rail, the methodcomprising: disengaging the wheel from the rail, the wheel beingattached to the railcar or locomotive; attaching a lathe machine to therail, the lathe machine including a compound slide system forpositioning the cutting tool in at least two axes and a computer controlfor controlling the compound slide system, the compound slide systemincluding a first motor and a second motor, the first motor foradjusting position in an X axis and the second motor for adjustingposition in a Y axis; rotating the wheel; and profiling the wheel inaccordance with a profile stored in the computer control of the lathemachine.
 5. The apparatus of claim 3 wherein the interface is configuredto ride on top of the rail associated with the wheel being engaged bythe tool.
 6. The apparatus of claim 3 wherein the interface includes alocator device configured to be placed along an edge of the railassociated with the wheel being engaged by the tool.
 7. The apparatus ofclaim 3 wherein the interface includes at least one clamp configured toengage the rail.
 8. The method of claim 1 wherein the lathe machineincludes a compound slide system for positioning the cutting tool in atleast two axes and a computer control for controlling the compound slidesystem, the computer control storing the profile.
 9. The apparatus ofclaim 3 wherein the interface includes a leveling mechanism that allowsthe apparatus to be selectively leveled when secured to the rail. 10.The method of claim 1 wherein the profile is a standard profile of astandard flange profile or a narrow flange profile.
 11. The method ofclaim 8 wherein the compound slide system includes a first motor and asecond motor, the first motor for adjusting position in an X axis andthe second motor for adjusting position in a Y axis.
 12. The method ofclaim 2 wherein the lathe machine includes a compound slide system forpositioning the cutting tool in at least two axes and a computer controlfor controlling the compound slide system, the computer control storingthe profile.
 13. The method of claim 4 wherein the step of rotating thewheel comprises using a motor associated with the locomotive to rotatethe wheel.
 14. The apparatus of claim 3 wherein the tool is a lathecutting tool.
 15. The apparatus of claim 3 wherein the compound slidesystem is releasably attachable to a rail.
 16. The apparatus of claim 3wherein the computer control receives at least four positions associatedwith the wheel.
 17. The apparatus of claim 16 wherein the at least fourpositions include at least one of a top of a flange of the wheel, anouter edge of the wheel, a first tread position of the wheel, and asecond tread riding position.
 18. The apparatus of claim 3 wherein thetool is a high grade carbide lathe cutting tool.
 19. The apparatus ofclaim 18 further comprising: a motor for engaging the wheel.
 20. Theapparatus of claim 19 wherein the motor is engaged via a bolt andsprocket or via a friction drive.